A General Vision for Reduction of Energy Consumption and CO2 Emissions from the Steel Industry

Material resource decoupling dilemma: Convergence and traps of in-use stock productivity in national economy development

Various studies have suggested decoupling material stock from economic output as an important measure for promoting sustainable development. Here, we develop three theoretical hypotheses to describe the evolution features and economic effects of material stock intensity, and predict in theory that (1) Countries with higher material stock intensity are more likely to decouple economic growth from material stock. (2) Material stock intensity follows convergence trends. (3) Higher material stock intensity leads to higher long-run economic growth rates. To examine the adaptability of these hypotheses, we choose steel in-use stock as the proxy for the material capital stock and use panel data in 85 countries from 1950 to 2018 to conduct empirical analysis. Our empirical results in most countries support the theoretical predictions of the hypotheses. In particular, a 0.1t/k$ increase in steel stock intensity leads to a 2.12% increase in the probability of decoupling between steel stock and economic output next year and a 0.34% increase in the long-run GDP per capita growth rate annually. Moreover, steel stock intensity converges to approximately 0.25t/k$ to 0.35t/k$ at mature development stages. We predict that, except China, which is expected to follow decoupling trends, other large developing economies will couple economic output with steel stock. However, the shape of intensity curves is still uncertain for highly developed countries in the future.

Correlating chemistry and mass transport in sustainable iron production

Steelmaking contributes 8% to the total CO2 emissions globally, primarily due to coal-based iron ore reduction. Clean hydrogen-based ironmaking has variable performance because the dominant gas-solid reduction mechanism is set by the defects and pores inside the mm- to nm-sized oxide particles that change significantly as the reaction progresses. While these governing dynamics are essential to establish continuous flow of iron and its ores through reactors, the direct link between agglomeration and chemistry is still contested due to missing measurements. In this work, we directly measure the connection between chemistry and agglomeration in the smallest iron oxides relevant to magnetite ores. Using synthesized spherical 10-nm magnetite particles reacting in H2, we resolve the formation and consumption of wüstite (Fe1-xO)-the step most commonly attributed to whiskering. Using X-ray diffraction, we resolve crystallographic anisotropy in the rate of the initial reaction. Complementary imaging demonstrated how the particles self-assemble, subsequently react, and grow into elongated "whisker" structures. Our insights into how morphologically uniform iron oxide particles react and agglomerate in H2 reduction enable future size-dependent models to effectively describe the multiscale aspects of iron ore reduction.

The Materials Science behind Sustainable Metals and Alloys

Production of metals stands for 40% of all industrial greenhouse gas emissions, 10% of the global energy consumption, 3.2 billion tonnes of minerals mined, and several billion tonnes of by-products every year. Therefore, metals must become more sustainable. A circular economy model does not work, because market demand exceeds the available scrap currently by about two-thirds. Even under optimal conditions, at least one-third of the metals will also in the future come from primary production, creating huge emissions. Although the influence of metals on global warming has been discussed with respect to mitigation strategies and socio-economic factors, the fundamental materials science to make the metallurgical sector more sustainable has been less addressed. This may be attributed to the fact that the field of sustainable metals describes a global challenge, but not yet a homogeneous research field. However, the sheer magnitude of this challenge and its huge environmental effects, caused by more than 2 billion tonnes of metals produced every year, make its sustainability an essential research topic not only from a technological point of view but also from a basic materials research perspective. Therefore, this paper aims to identify and discuss the most pressing scientific bottleneck questions and key mechanisms, considering metal synthesis from primary (minerals), secondary (scrap), and tertiary (re-mined) sources as well as the energy-intensive downstream processing. Focus is placed on materials science aspects, particularly on those that help reduce CO₂ emissions, and less on process engineering or economy. The paper does not describe the devastating influence of metal-related greenhouse gas emissions on climate, but scientific approaches how to solve this problem, through research that can render metallurgy fossil-free. The content is considering only direct measures to metallurgical sustainability (production) and not indirect measures that materials leverage through their properties (strength, weight, longevity, functionality).

Measures to reduce corporate GHG emissions: A review-based taxonomy and survey-based cluster analysis of their application and perceived effectiveness

Companies contribute to a large extent to greenhouse gas emission. To mitigate this, measures for reducing these emissions can be applied. There is, however, neither a systematized general overview of existing measures nor an estimation of their application and their effectiveness to reduce greenhouse gas emissions. This study strives to close this gap by reviewing research on the reduction of corporate greenhouse gas emissions and synthesizing emission reduction measures in a taxonomy. Furthermore, the application of these measures and their perceived effectiveness is empirically assessed using a survey among companies that are involved in emission reduction activities. On this basis, a cluster analysis is conducted to identify measure types and to unveil application patterns. 27 different measures and 65 respective implementation examples are identified and structured within nine categories: energy, product, process, technology, 6R and waste management, office and mobility, management, reporting and disclosure, and compensation measures. The empirical analysis shows that there exist measures with a high efficiency to reduce emission, which are rarely applied in companies. On the other side, a large share of applied measures is not perceived as highly effective. Companies can use these results to structure their emission reduction activities and identify best practices.

What Shall We Do with Steel Mill Off-Gas: Polygeneration Systems Minimizing Greenhouse Gas Emissions

Both the global steel and chemical industries contribute largely to industrial greenhouse gas (GHG) emissions. For both industries, GHG emissions are strongly related to the consumption of fossil resources. While the chemical industry often releases GHGs as direct process emissions, steel mills globally produce 1.78 Gt of off-gases each year, which are currently combusted for subsequent heat and electricity generation. However, these steel mill off-gases consist of high value compounds, which also can be utilized as feedstock for chemical production and thereby reduce fossil resource consumption and thus GHG emissions. In the present work, we determine climate-optimal utilization pathways for steel mill off-gases. We combine a nonlinear, disjunctive model of the steel mill off-gas separation system with a large-scale linear model of the chemical industry to perform environmental optimization. The results show that the climate-optimal utilization of steel mill off-gases depends on electricity's carbon footprint: For the current electricity grid mix, methane, hydrogen, and synthesis gas are recovered as feedstocks for conventional chemical production and enable a methanol-based chemical industry. For low electricity footprints in the future, the separation of steel mill off-gases supports CO₂-based production processes in the chemical industry, supplying up to 30% of the required CO₂. By coupling the global steel and chemical industry, industrial GHG emissions can be reduced by up to 79 Mt CO₂-equivalents per year. These reductions provide up to 4.5% additional GHG savings compared to a stand-alone optimization of the two industries, showing a limited potential for this industrial symbiosis.

Bioelectrochemical methanation by utilization of steel mill off-gas in a two-chamber microbial electrolysis cell

Carbon capture and utilization has been proposed as one strategy to combat global warming. Microbial electrolysis cells (MECs) combine the biological conversion of carbon dioxide (CO₂) with the formation of valuable products such as methane. This study was motivated by the surprising gap in current knowledge about the utilization of real exhaust gas as a CO₂ source for methane production in a fully biocatalyzed MEC. Therefore, two steel mill off-gases differing in composition were tested in a two-chamber MEC, consisting of an organic substrate-oxidizing bioanode and a methane-producing biocathode, by applying a constant anode potential. The methane production rate in the MEC decreased immediately when steel mill off-gas was tested, which likely inhibited anaerobic methanogens in the presence of oxygen. However, methanogenesis was still ongoing even though at lower methane production rates than with pure CO₂. Subsequently, pure CO₂ was studied for methanation, and the cathodic biofilm successfully recovered from inhibition reaching a methane production rate of 10.8 L m⁻²d⁻¹. Metagenomic analysis revealed Geobacter as the dominant genus forming the anodic organic substrate-oxidizing biofilms, whereas Methanobacterium was most abundant at the cathodic methane-producing biofilms.

Comparative Analysis of the Global Warming Potential (GWP) of Structural Stone, Concrete and Steel Construction Materials

The manufacturing and construction industries have always been large contributors to global CO2 emissions, largely as a consequence of material choices. Two of the most commonly used building materials are concrete and steel, but both of these industries have been identified as large sources of atmospheric CO2. Therefore, reducing the use of these materials and finding alternatives to them that meet the engineering requirements of a design, while also minimizing emissions, is becoming increasingly important. Stone in its natural form is a zero-carbon emission material and has strong physical properties that make it a viable substitute for concrete and steel, across a range of applications. Yet research into the potential use of stone by the construction industry remains rare. The aim of this research is to investigate whether the use of stone as a building product is a feasible alternative in terms of carbon emissions. This study compares data from 11 Environmental Product Declarations (EPDs) that provide Life Cycle Analysis (LCA) assessments of their considered product (i.e., types of dimensional stone, concrete, or steel). However, this research also highlights some shortcomings in the EPDs that point to a need for greater legitimate engagement with this tool, and for more consistency between the data being presented in EPDs. Global Warming Potential (GWP) data are compared between products to determine the difference in carbon emissions. The results indicate that GWP values for dimensional structural stone (135 kg.CO2/m3) are 45–75% lower than the concrete products considered in this investigation (246–514 kg.CO2/m3), and over 99% lower than certain steel products (22,294–29,202 kg.CO2/m3). This research indicates that stone is demonstrably better in terms of its GWP, and that a more extensive use of structural stone represents a key opportunity for the construction industry to reduce its CO2 emissions.

Future of Hydrogen as an Alternative Fuel for Next-Generation Industrial Applications; Challenges and Expected Opportunities

A general rise in environmental and anthropogenically induced greenhouse gas emissions has resulted from worldwide population growth and a growing appetite for clean energy, industrial outputs, and consumer utilization. Furthermore, well-established, advanced, and emerging countries are seeking fossil fuel and petroleum resources to support their aviation, electric utilities, industrial sectors, and consumer processing essentials. There is an increasing tendency to overcome these challenging concerns and achieve the Paris Agreement’s priorities as emerging technological advances in clean energy technologies progress. Hydrogen is expected to be implemented in various production applications as a fundamental fuel in future energy carrier materials development and manufacturing processes. This paper summarizes recent developments and hydrogen technologies in fuel refining, hydrocarbon processing, materials manufacturing, pharmaceuticals, aircraft construction, electronics, and other hydrogen applications. It also highlights the existing industrialization scenario and describes prospective innovations, including theoretical scientific advancements, green raw materials production, potential exploration, and renewable resource integration. Moreover, this article further discusses some socioeconomic implications of hydrogen as a green resource.

A New Methodological Approach on the Characterization of Optimal Charging Rates at the Hydrogen Plasma Smelting Reduction Process Part 2: Results

To meet the target for anthropogenic greenhouse gas (GHG) reduction, the European steel industry is obliged to reduce its emissions. A possible pathway to reach this requirement is through developments of new technologies for a GHG-free steel production. One of these processes is the hydrogen plasma smelting reduction (HPSR) developed since 1992 at the Chair of Ferrous Metallurgy at the Montanuniversitaet Leoben in Austria. Based on the already available publication of the methodology in this work, potential process parameters were investigated that influence the reduction kinetics during continuous charging to improve the process further. Preliminary tests with different charging rates and plasma gas compositions were carried out to investigate the impacts on the individual steps of the reduction process. In the main experiments, the obtained parameters were used to determine the effect of the pre-reduction degree on the kinetics and the hydrogen conversion. Finally, the preliminary and main trials were statistically evaluated using the program MODDE^® 13 Pro to identify the significant influences on reduction time, oxygen removal rate, and hydrogen conversion. High hydrogen utilization degrees could be achieved with high iron ore feeding rates and low hydrogen concentrations in the plasma gas composition. The subsequent low reduction degree and thus a high proportion of oxide melt leads to a high oxygen removal rate in the post-reduction phase and, consequently, short process times. Calculations of the reduction constant showed an average value of 1.13 × 10⁻⁵ kg oxygen/m² s Pa, which is seven times higher than the value given in literature.

Feasibility Study of Bio-Sludge Hydrochar as Blast Furnace Injectant

Hydrothermal treatment can convert paper mill biological (bio-) sludge waste into more energy-dense hydrochar, which can achieve energy savings and fossil CO2 emissions reduction when used for metallurgical applications. This study assesses the basic, combustion and safety performance of bio-sludge hydrochar (BSHC) to evaluate its feasibility of use in blast furnace injection processes. When compared to bituminous and anthracite coals, BSHC has high volatile matter and ash content, and low fixed carbon content, calorific value and ignition point. The Ti and Tf values of BSHC are lower and the combustion time longer compared to coal. The R0.5 value of BSHC is 5.27 × 10−4 s−1, indicating a better combustion performance than coal. A mixture of BSHC and anthracite reduces the ignition point and improves the ignition and combustion performance of anthracite: an equal mixture of BSHC and anthracite has a R0.5 of 3.35 × 10−4 s−1. The explosiveness of BSHC and bituminous coal is 800 mm, while the explosiveness of anthracite is 0 mm. A mixture of 30% BSHC in anthracite results in a maximum explosiveness value of 10 mm, contributing to safer use of BSHC. Mixing BSHC and anthracite is promising for improving combustion performance in a blast furnace while maintaining safe conditions.

City-Level Transition to Low-Carbon Economy

In recent years climate change has emerged as a global issue directly related to quality of life. In this context, one of the key goals in the next few decades will be to transition the global economy to a sustainable system. The nature of the energy planning process dictates the application of complex models. There is no universal solution to the energy planning problem. Each territory requires a bespoke strategy aimed at utilising its specific potential. The research presented in this paper explores reaching a zero-carbon energy system at the city level. It establishes a step-by-step decarbonisation method and proposes an energy transition index (ETI). The index presented is used to evaluate different renewable energy sources (RES) deployment scenarios in the context of affordability, self-reliance, and sustainability. The main aspects and barriers of deploying sustainable energy solutions are also explored. Some of the key challenges of RES deployment are identified as capital intensity, output variability, and the regulatory framework. The approach applied in the paper focuses on a city-level strategy in line with the goal of satisfying demand through local energy sources. The presented analysis offers two basic conclusions: (1) each territory requires a bespoke strategy that can optimally utilise its energy potential and (2) building a local zero-carbon system can be feasible only by implementing energy storage technologies.

A Review on the Kinetics of Iron Ore Reduction by Hydrogen

A clean energy revolution is occurring across the world. As iron and steelmaking have a tremendous impact on the amount of CO₂ emissions, there is an increasing attraction towards improving the green footprint of iron and steel production. Among reducing agents, hydrogen has shown a great potential to be replaced with fossil fuels and to decarbonize the steelmaking processes. Although hydrogen is in great supply on earth, extracting pure H₂ from its compound is costly. Therefore, it is crucial to calculate the partial pressure of H₂ with the aid of reduction reaction kinetics to limit the costs. This review summarizes the studies of critical parameters to determine the kinetics of reduction. The variables considered were temperature, iron ore type (magnetite, hematite, goethite), H₂/CO ratio, porosity, flow rate, the concentration of diluent (He, Ar, N₂), gas utility, annealing before reduction, and pressure. In fact, increasing temperature, H₂/CO ratio, hydrogen flow rate and hematite percentage in feed leads to a higher reduction rate. In addition, the controlling kinetics models and the impact of the mentioned parameters on them investigated and compared, concluding chemical reaction at the interfaces and diffusion of hydrogen through the iron oxide particle are the most common kinetics controlling models.

A Numerical Study on the Performance of the H2 Shaft Furnace with Dual-Row Top Gas Recycling

Given the urgent pursuit of carbon neutrality and stringent climate policies, the H2 shaft furnace (H2-SF) is starting to gain widespread attention in the steel industry. In this study, the performance of the H2-SF under operation with a dual-row injection top gas recycling system was investigated by a one-dimensional mathematical model. The potential of microwave heating as a means to supply thermal energy in regions of energy deficit was also assessed briefly. The results showed that for scenarios without microwave heating, increasing the upper-row injection rate can improve the furnace performance, and increasing the distance of the upper-row injection level from the furnace top also has a positive effect. A high microwave heating efficiency is expected in regions above the upper-row injection level. For scenarios with microwave heating, a higher microwave power leads to a better furnace performance. Thus, a higher furnace productivity can be achieved by increasing either the upper-row injection rate or the microwave power. However, the latter seems more promising as it decreases the total energy demand due to a better utilization of thermal energy. Based on the comparison of two representative examples, the decrease in the total energy demand is about 0.2 GJ/t-Fe.

Evaluating the Effect of MgO/Al2O3 Ratio on Thermal Behaviors and Structures of Blast Furnace Slag with Low Carbon Consumption

In order to clarify the effect of the MgO/Al2O3 ratio on the fluidity of a low-alumina blast furnace slag system, the influence law of slag fluidity with different MgO/Al2O3 ratios was studied based on the composition of blast furnace slag through a viscosity experiment and themodynamic software. By studying the effect of the MgO/Al2O3 ratio on the activation energy of viscous flow of slag combined with FT-IR, the effect of the MgO/Al2O3 ratio on the thermal-stability of low-aluminum slag was interpreted from the microstructure level. Results indicated that the viscosity and the melting temperature of slag both showed a gradual downward trend due to the increase of the MgO/Al2O3 ratio. Besides, the temperature stability of the low aluminum slag became more stable due to the depolymerization of the complex structure of slag. Considering the actual operating conditions of blast furnace, the MgO/Al2O3 ratio of slag was suggested to be controlled to 0.60 and the basicity to be no higher than 1.20 under the conditions of this investigation. Industrial test results showed that the coke rate could be saved as 3.49 kg/t when the MgO/Al2O3 ratio decreased from 0.70 to 0.58.

An Economic Model to Assess Profitable Scenarios of EAF-Based Steelmaking Plants under Uncertain Conditions

The steelmaking processes are considered extremely energy-intensive and carbon-dependent processes. In 2018, it was estimated that the emissions from global steel production represented 7–9% of direct emissions generated by fossil fuels. It was estimated that a specific emissions value of 1.8 tCO2 per ton of steel was produced due to the carbon-dependent nature of the traditional blast furnace and basic oxygen furnace (BF-BOF) route. Therefore, it is necessary to find an alternative solution to the BF-BOF route for steel production to counteract this negative trend, resulting in being sustainable from an environmental and economic point of view. To this concern, the objective of this work consists of developing a total cost function to assess the economic convenience of steelmaking processes considering the variability of specific market conditions (i.e., iron ore price, scraps price, energy cost, etc.). To this purpose, a direct reduction (DR) process fueled with natural gas (NG) to feed an electric arc furnace (EAF) using recycled steel scrap was considered. The approach introduced is totally new; it enables practitioners, managers, and experts to conduct a preliminary economic assessment of innovative steelmaking solutions under market uncertainty. A numerical simulation has been conducted to evaluate the profitability of the investment considering the economic and environmental costs. It emerged that the investment is profitable in any case from an economic perspective. On the contrary, considering the environmental costs, the profitability of the investment is not guaranteed under certain circumstances.

Assessment of the Multiannual Impact of the Grape Training System on GHG Emissions in North Tajikistan

The overarching goal of agricultural sciences is to optimize production technology to rationalize the use of production resources, energy, and space. Due to its high fertilization and water requirements, the vine is a plant with a high potential for greenhouse gas (GHG) emissions. The modifying factor in the production technology is plantation management. To reach the assumed goal, a field experiment was conducted in the years 2001–2020, and the following training systems were used: multi-arm fan system (A) trunk height <30 cm, (B) 80 cm, (C) 120 cm, one-side multi-arm, paired planting (D) 120 cm, (E) 140 cm. The total amount of GHGs emitted in vine cultivation was calculated according to ISO 14040 and ISO 14044 standards. The system boundaries were: establishing the plantation, the production and use of fertilizers and pesticides, energy consumption for agricultural treatments, and gas emissions from the soil. The amount of GHG emissions for cultivation using the systems A, B, C ranged from 426.77 to 556.34 kg of CO2-eq Mg of yield−1, while in the case of D and E systems, the value was approx. 304.37 to 306.23 CO2-eq Mg of yield−1. When comparing this stage with total annual emissions related to cultivation (for 1 ha), the amount of emitted GHGs at this stage is from approx. 42% to 58% higher than from annual emission related to cultivation. Concrete poles are the main element related with GHG emission during stage of plantation establishment, from 97 to 98% of emission. In the case of annual production, nitrogen fertilizers are responsible for approx. 36%. Moreover, the results show that systems D and E increased the average annual fruit yield (per 19 years of research) by approx. 68% compared to the A, B, C systems. There was no difference in the yield of plants with different height of shoots in the D and E systems. The “one-side, multi-arm, paired planting system” was characterized by the highest production and environmental efficiency.

Application of Liquid Hydrogen Carriers in Hydrogen Steelmaking

Steelmaking is responsible for approximately one third of total industrial carbon dioxide (CO2) emissions. Hydrogen (H2) direct reduction (H-DR) may be a feasible route towards the decarbonization of primary steelmaking if H2 is produced via electrolysis using fossil-free electricity. However, electrolysis is an electricity-intensive process. Therefore, it is preferable that H2 is predominantly produced during times of low electricity prices, which is enabled by the storage of H2. This work compares the integration of H2 storage in four liquid carriers, methanol (MeOH), formic acid (FA), ammonia (NH3) and perhydro-dibenzyltoluene (H18-DBT), in H-DR processes. In contrast to conventional H2 storage methods, these carriers allow for H2 storage in liquid form at moderate overpressures, reducing the storage capacity cost. The main downside to liquid H2 carriers is that thermochemical processes are necessary for both the storage and release processes, often with significant investment and operational costs. The carriers are compared using thermodynamic and economic data to estimate operational and capital costs in the H-DR context considering process integration options. It is concluded that the use of MeOH is promising compared to the other considered carriers. For large storage volumes, MeOH-based H2 storage may also be an attractive option to the underground storage of compressed H2. The other considered liquid H2 carriers suffer from large thermodynamic barriers for hydrogenation (FA) or dehydrogenation (NH3, H18-DBT) and higher investment costs. However, for the use of MeOH in an H-DR process to be practically feasible, questions regarding process flexibility and the optimal sourcing of CO2 and heat must be answered.

Numerical Investigation of Blast Furnace Operation with Scrap Charging

One approach to reduce CO2 emission in the steelmaking industry is to recycle scrap to the blast furnace/basic oxygen furnace (BF/BOF) production system. This paper performed a numerical investigation on the BF operation with scrap charging. The investigated BF was with an inner volume of 820 m3, producing 2950 tons of hot metal per day (tHM/d). The simulated results indicated the following: Extra scrap addition in BF causes the decrease of shaft temperature, the decrease of local gas utilization, and the lowering of cohesive zone position, leading to an unstable BF running. The partial replacement of sinter with scrap in BF can mitigate the negative effects induced by scrap charging. The optimal scrap rate in the BF is 178 kg/tHM, under which the BF reaches a productivity of 3310 tHM/d, a top-gas utilization of 48.5%, and a top-gas temperature of 445 K. Compared to the base case, in the BF operation with scrap charging, the BF productivity is increased by 360 kg/tHM, its pulverized-coal rate and coke rate are decreased by 16.3 kg/tHM and 39.8 kg/tHM, respectively.